INDUSTRIAL TRAINING

UDAIPUR CEMENT INDUSTRIES LIMITED

Sijan Rai 110106267

INDUSTRY BACKGROUND

• Udaipur Cement Industries Ltd is a fully Government owned industry in Nepal, established on 14th June, 1987.

• The source of financing of the project is Japanese government assistance of 18 billion 77 crore Japanese yen and equity share of Nepal Government of 45 crore .

• The construction of the project started in September 1989 and was completed in Oct,1992.The commencement of commercial production started from the January 1993.

• The Industry Produces 2,77,200 MT Cement per Year Ordinary Portland Cement (OPC) .

• Consulting Engineer: Onoda Engineering Co.Ltd.Japan.

• Turnkey Contractor: Consortium of Kawasaki Heavy Industries Ltd and Tomen Corporation –Japan.

Annual Requirement

• Lime Stone:3,30,000 MT. (Has its own mine )

• Iron Ore :4,000 MT.(Imported from India )

• Clay :57,000~82,500 MT.(own min)

• Gypsum :10,500 MT.(Imported From India )

• Silica Sand : up to 21,000MT.(Own Mine)

• Fuel requirement(i) Coal 50,000MT/Year (ii) Furnace Oil :12,000 KL.

• Electricity: 8000KW.

• Water 1500 M3/ Day.

Organizational Structure:

00. Limestone Quarry and Crushing plant

09. Cooler

01. Limestone Stockpile 10. Deep Bucket Conveyor

02. Additives Hopper 11/12. Clinker/Gypsum Storage

03. Additives Storage 13. Coal Mill Building

04. Raw Mill Building 14. Cement Mill and Bag House

05. Blending and Storage Silo 15. Cement Storage Silo

06. Preheater 16. Packing & Dispatch

07. Gas Conditioning Tower and ESP 17. Central Control Room

08. Kiln

Limestone Mine

I. Udaipur Cement Industry had its own mine .

II. Limestone mine is a 30 km away from the main plant site .

III. The limestone mine is mined by using opencast method where the bench are made and blasted off using explosives.

IV. Then with the help of Dump truck it is placed on primary crusher and through the help of ropeway the limestone is brought to the plant site .

RopewayI. Ropeway is used to

transport the limestone from the quarry site to the main plant which is almost 30 km away from the plant .

II. The total length of the ropeway is around 13.8 km long .

III. The ropeway was built by German Company .The ropeway moves at a speed of around 10 km per hour .

IV. There are almost 50 supporting towers to support the load of the buckets .

CrusherI. The crushing of big limestone is carried out in

two stages through primary crushing and

secondary crushing .

II. Once the limestone arrives at the plant it is put

into primary crusher where the large size of

limestone is crushed into smaller pieces .

III. Jaw crusher is used in primary crushing .

IV. The after primary crusher through the help of

conveyer belt the limestone is put into

secondary crusher .

V. In secondary crusher the limestone pieces are

broken down into less than 20 mm size . Impact

crusher is used in secondary crushing .

Scrabber And Reclaimer Stacker

Limestone Storage

Stacker :It contains Belt

conveyers .It is continuous moving parts and collect the stone coming from the crusher by stacking motion .

Scrabber :It is a triangular arm positioned one the two sides of reclaimer .It consist of armature with rod in perpendicular direction which moves to and fro motion

Reclaimer: A reclaimer is a large machine used in bulk material handling applications. A reclaimer's function is to recover the limestone from storage to the belt .

Raw Mill:

I. The raw material is finish-ground before being fed into the kiln for clinkering.

II. This grinding is done using either ball mills or vertical roller mills (VRM).

III. . The choice between a ball mill and VRM is governed by many factors such as the moisture content of the raw material, the size of the plant, the abrasiveness of the material, the energy consumption levels, reliability, and finally financial consideration

IV. VRM uses the compression principle to grind the raw material.

Blending Silo

I. In order to blend and

homogenize the raw materials

properly, continuous blending

silos are used.

II. The blending silo can store

6000 tons of the powder

mixture.

III. It is highly insulated so that it

can maintain the appropriate

temperature of the powder

mixture.

Pre Heater Tower I. The key component of the gas-

suspension preheater is the cyclone. II. A cyclone is a conical vessel into which a

dust-bearing gas-stream is passed tangentially.

III. A very efficient heat exchange takes place the gas is efficiently cooled, hence producing less waste of heat to the atmosphere, and the raw mix is efficiently heated.

IV. This efficiency is further increased if a number of cyclones are connected in sequence.

Rotatory Kiln

I. The kiln is a cylindrical vessel, inclined at around 15 degree to the horizontal, which is rotated slowly about its axis.

II. The kiln feed is fed into the upper end of the cylinder.

III. As the kiln rotates, material gradually moves down towards the lower end, and may undergo a certain amount of stirring and mixing.

IV. Hot gases passes along the kiln in the opposite direction (counter-current) to that of kiln feed. The hot gases is generated by a flame inside the kiln.

V. Such a flame is projected from a burner-pipe (or "firing pipe") which acts like a large Bunsen burner.

Cement MillI. It is the equipment used to grind the

hard, nodular clinker from the cement kiln and gypsum into the fine grey powder that is cement. The iron ball also known as grinding media of different size are used for grinding.

II. The cement mill consists of two compartment separated by the diapharm .

III. The primary compartment consists of iron ball of bigger size whereas the secondary compartment consists of ball of smaller size.

IV. The clinkers are grinded into primary compartment and then sucked into the secondary compartment through the diapharm.

V. Now this clinker is further grinded into powder form which is then sucked to the separator,then cyclone and finally stored into the cement silo.

Material Handling Devices :

Belt Conveyer Bucket Elevator

Screw Conveyer

Electrostatic PrecipitatorI. It contains a row of thin vertical wires, and

followed by a stack of large flat metal plates oriented vertically, with the plates typically spaced about 1 cm to 18 cm apart.

II. The air or gas stream flows horizontally through the spaces between the wires, and then passes through the stack of plates.

III. A negative voltage of several thousand volts is applied between wire and plate. If the applied voltage is high enough, an electron discharge ionizes the gas around the electrodes.

IV. Negative ions flow to the plates and charge the gas-flow particles.

V. The ionized particles, following the negative electric field created by the power supply, move to the grounded plates.

VI. The particles are collected whereas the gas is released to atmosphere .

Thank You